Claims:We claim:
1. A fuel level sensor assembly (100) for a vehicle, comprising:
a fuel suction tube (1) connected to a mounting flange (2) is configured within a fuel tank of the vehicle , wherein the fuel suction tube (1) is slidably mounted on a first arm (1a) having a plurality of serrations (8a);
a clamp (3) mounted to the fuel suction tube (1) and adapted to support at least one sensor unit (4); and
a first float arm (5a) pivotally connected to the at least one sensor unit (4), wherein the first float arm (5a) is slidably connected to one end of a second float arm (5b) and other end of the second float arm (5b) is connected to a float (11), wherein the second float arm (5b) includes a plurality of serrations (8b), and
the plurality of serrations (8a and 8b) facilitates adjusting length of the first arm (1a) and the second float arm (5b), while assembling the fuel level sensor assembly (100) inside the fuel tank of the vehicle.

2. The fuel level sensor assembly (100) as claimed in claim 1, wherein the clamp (3) is slidable along and about the axis (A-A’) to adjust position of the clamp (3) on the fuel suction tube (1).

3. The fuel level sensor assembly (100) as claimed in claim 1, wherein the first arm (1a) is lockable to the fuel suction tube (1) at each of the plurality of serrations (8a) by a first locking member (9).

4. The fuel level sensor assembly (100) as claimed in claim 1, wherein the second float arm (5b) is lockable to the first float arm (5a) at each of the plurality of serrations (8b) by a second locking member (10).

5. The fuel lever sensor assembly (100) as claimed in claim 1, wherein the first arm (1a) is connected to a fuel filter (6).

6. The fuel level sensor assembly (100) as claimed in claim 1, wherein the at least one sensor unit (4) is a Thin Film Resistor [TFR] sensor unit.

7. The fuel level sensor assembly (100) as claimed in claim 1, wherein the fuel suction tube (1), the at least one sensor unit (4) and the second float arm (5b) are adjusted corresponding to profile of the fuel tank.

8. The fuel level sensor assembly (100) as claimed in claim 1, comprises a washer member (7) provided at an interface of the fuel suction tube (1) for seating the first arm (1a).

9. The fuel level sensor assembly (100) as claimed in claim 1, comprises a bracket (3a) extending from the clamp (3), for fastening the at least one sensor unit (4).

10. A fuel tank comprising a fuel level sensor assembly (100) as claimed in claim 1.
, Description:TECHNICAL FIELD
Present disclosure generally relates to a field of automobiles. Particularly, but not exclusively, the present disclosure relates to a fuel level sensor assembly for a fuel tank of a vehicle. Further, embodiments of the present disclosure disclose the fuel level sensor assembly configurable or customisable based on dimensions of the fuel tank.

BACKGROUND OF THE DISCLOSURE
In recent past, vehicles have undergone rapid evolution in all facets of technology such as performance, safety, aesthetic appeal, fuel efficiency and the like. Sophisticated vehicle parts are being manufactured by automobile manufacturers for improving characteristics of the vehicles to suit customer needs. In general, such sophisticated vehicle parts, undergo various modifications to meet market supremacy by either altering design of the vehicle part or by integration of multiple parts that brings out efficiency from such parts.

Further, as a marketing strategy, automobile manufacturers are manufacturing and selling vehicles of various segments, ranging from hatchbacks, sedans, sports utility vehicle SUV’s, light commercial vehicles LCV’s and the like. Consequently, the specification of each of these vehicle parts changes corresponding to each segment of the vehicle.

However, the process of manufacturing vehicle parts for various segments of the vehicle, requires the automobile manufacturer to produce vehicle parts, keeping each vehicle specification in mind. Particularly, for vehicle parts such as but not limiting to the fuel level sensor assembly, wherein the automobile manufacturer has to produce the fuel level sensor assembly based on dimension of the fuel tank of each of the vehicle variants. Additionally, the profile of the fuel tank of each of these vehicle variants, varies which adds on to the problem of manufacturing separate fuel level sensor assemblies for each of the vehicle variants. Thus, this process, significantly hampers carry-over of parts, inherently making the production process time consuming and costly. Consequently, mass production of the vehicle parts are impaired, which is undesirable.

Thus, there exists a need for a fuel level sensor assembly, which can be adjusted corresponding to the profile of the fuel tank of the vehicle.

The information disclosed in this background of the disclosure section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.

SUMMARY OF THE DISCLOSURE
One or more drawbacks of conventional fuel level sensor assembly are overcome, and additional advantages are provided through the fuel level sensor assembly as claimed in the present disclosure. Additional features and advantages are realized through the technicalities of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered to be a part of the claimed disclosure.

In one non-limiting embodiment of the present disclosure, a fuel level sensor assembly is disclosed. The fuel level sensor assembly comprising a fuel suction tube connected to a mounting flange and configured within a fuel tank of the vehicle, wherein the fuel suction tube is slidably mounted on a first arm having a plurality of serrations. A clamp is mounted to the fuel suction tube and is adapted to support at least one sensor unit. A first float arm is pivotally connected to the at least one sensor unit, the first float arm is slidably connected to one end of a second float arm and other end of the second float arm is connected to a float, wherein the second float arm includes a plurality of serrations. The plurality of serrations facilitates adjusting length of the first arm and the second float arm, while assembling the fuel level sensor assembly inside the fuel tank of the vehicle.

In an embodiment, the clamp is slidable along and about the axis (A-A’) to adjust the position of the clamp on the fuel suction tube.

In an embodiment, the first arm is lockable to the fuel suction tube at each of the plurality of serrations by a first locking member.

In an embodiment, the second float arm is lockable to the first float arm at each of the plurality of serrations by a second locking member.

In an embodiment, the first arm is connected to a fuel filter.

In an embodiment, the at least one sensor unit is a Thin Film Resistor [TFR] sensor unit.

In an embodiment, the fuel suction tube, the at least one sensor unit and the second float arm are adjusted corresponding to profile of the fuel tank.

In an embodiment, a washer member is provided at an interface of the fuel suction tube for seating the first arm.

In an embodiment, a bracket extends from the clamp, for fastening the at least one sensor unit.

It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The novel features and characteristics of the disclosure are set forth in the appended description. The disclosure itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:

Figure 1 illustrates a schematic of a fuel level sensor assembly for a vehicle, in accordance with an embodiment of the present disclosure.

Figure 2 illustrates a magnified view of one end of a fuel suction pipe of the fuel level sensor assembly of Figure 1.

Figure 3 illustrates a magnified view of the fuel level sensor assembly, depicting mounting of a clamp with the fuel suction pipe, in accordance with an embodiment of the present disclosure.

Figure 4a illustrates a side view of a first float arm and a second float arm connected to the at least one sensor unit of the fuel level sensor assembly, in accordance with an embodiment of the present disclosure.

Figure 4b illustrates a magnified view of the fuel level sensor of portion A disclosed in Figure 1.

Figure 4c illustrates a magnified view of the fuel level sensor of portion B disclosed in Figure 1.

Figure 4d illustrates another magnified view of the fuel level sensor of portion A disclosed in Figure 1.

The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION OF THE DISCLOSURE

While the embodiments of the disclosure are subject to various modifications and alternative forms, specific embodiment thereof have been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.

It is to be noted that a person skilled in the art would be motivated from the present disclosure to arrive at a fuel level sensor assembly for a vehicle. The fuel level sensor assembly may vary based on the configuration of a fuel tank of the vehicle. However, such modifications should be construed within the scope of the disclosure. Accordingly, the drawings illustrate only those specific details that are pertinent to understand the embodiments of the present disclosure, so as not to obscure the disclosure with details that will be clear to those of ordinary skill in the art having benefit of the description herein.

The terms “comprises”, “comprising”, or any other variations thereof used in the disclosure, are intended to cover a non-exclusive inclusion, such that a device, system, assembly that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such system, or assembly, or device. In other words, one or more elements in a system or device proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or device.

Embodiments of the present disclosure disclose a fuel level sensor assembly for a vehicle. The fuel level sensor assembly, is configured to be adjustable based on profile of a fuel tank of the vehicle. The fuel level sensor assembly comprises a fuel suction tube connected to a mounting flange, and is configured within the fuel tank of the vehicle. The fuel suction tube is slidably mounted to a first arm having a plurality of serrations. The plurality of serrations are configured to receive a first locking member, which facilitates adjustment of length of the first arm with respect to the fuel suction tube. This configuration of the fuel suction tube, thus ensures that the vertical height of the fuel level sensor assembly is calibrated corresponding to the vertical dimension of the fuel tank. Further, a clamp is mounted to the fuel suction tube, which is configured to support at least one sensor unit. The clamp is configured to rotate about an axis (A-A’) and to slide along the axis (A-A’) for adjusting the position of the clamp on the fuel suction tube. This configuration of the clamp ensures that, the position of the at least one sensor unit is adjusted corresponding to the profile of the fuel tank. The fuel level sensor assembly further includes a first float arm pivotally connected to the at least one sensor unit, wherein the at least one sensor unit is configured to detect fuel level in the fuel tank based on the pivotal motion of the first float arm. The first float arm is slidably connected to one end of the second float arm, which includes a plurality of serrations. The second float arm also includes a float at the other end, which pivotally actuates the first float arm. The plurality of serrations are configured to receive a second locking member, which facilitates adjustment of length of the second float arm with respect to the first float arm. This configuration of the second float arm, ensures adjustment in position of the float arm and the float corresponding to the profile of the fuel tank.

The following paragraphs describe the present disclosure with reference to figures 1 to 4c. In the figures, the same element or elements which have similar functions are indicated by the same reference signs.

Figure 1 in one exemplary embodiment of the present disclosure, illustrates a schematic view of a fuel level sensor assembly (100) for a vehicle. The fuel level sensor assembly (100) is configured to be adjustable corresponding to profile of a fuel tank of the vehicle.

The fuel level sensor assembly (100) comprises a fuel suction tube (1) connected to a mounting flange (2) and is configured within the fuel tank [not shown in Figures] of the vehicle. The fuel suction tube (1) further comprises a clamp (3) mounted to the fuel suction tube (1) wherein the clamp (3) is adapted to support an at least one sensor unit (4) and a first float arm (5a) and a second float arm (5b). Further, the fuel suction tube (1) at one end, is connected to a first arm (1a). The fuel suction tube (1) may be connected to a motor for pumping fuel from the fuel tank to an engine of the vehicle [not shown in Figures].

Referring to Figure 2 in conjunction with Figure 1, the fuel suction tube (1) is slidably mounted to the first arm (1a), which includes a plurality of serrations (8a), wherein each of the plurality of serrations (8a) are configured to receive a first locking member (9) for locking the first arm (1a) within the fuel suction tube (1). The plurality of serrations (8a) are configured to adjust length of the first arm (1a) within the fuel suction tube (1), based on vertical dimension of the fuel tank of the vehicle. As an example, the first arm (1a) may be adjusted by sliding within the fuel suction tube (1) wherein any one of the plurality of serrations (8A) secures to the first locking member based on the requirement of the dimension of the fuel tank. Further, a washer member (7) may be provided at an interface of the fuel suction tube (1) for seating the first arm (1a). The washer member (7) ensures that the, first arm (1a) is rigidly fitted with the fuel suction tube (1).

In an embodiment, one end of the first arm (1a) includes the plurality of serrations (8a), while other end of the first arm (1a) is connected to a fuel filter (6) for filtering the fuel sucked into the fuel suction tube (1).

In an embodiment, distance between each of the plurality of serrations (8a) are selected based on the profile of the fuel tank of vehicles in various segments, so that the length of the fuel suction tube (1) is calibrated corresponding to the profile of the fuel tank. In an embodiment, the distance between each of the plurality of serrations (8a) may be in a range of about 10mm to about 20 mm.

In an exemplary embodiment, the plurality of serrations (8a) may be five in number, which enable variation of the vertical height of the fuel suction tube (1) by five levels. However, this should not be construed as a limitation in adjusting the height by only five levels as different fuel tank dimensions may require adjustment of height by less than or more than 5 levels.

Referring back to Figure 1, the clamp (3) which is mounted on the fuel suction tube (1) and is adapted to support the at least one sensor unit (4). The clamp (3) is mounted such that, it is slidable along an axis (A-A’) of the fuel suction tube (1) and hence, this enables adjustment of the position of the clamp (3) and the at least one sensor unit (4), along the fuel suction tube (1). The clamp (3) is also adapted to be rotated about the axis (A-A’) and thus enables adjustment of an angular position of the clamp (3) and the at least one sensor unit (4), on the fuel suction tube (1). This configuration of the clamp (3) enables adjustment of position of the at least one sensor unit (4) corresponding to profile of the fuel tank.

Further, the at least one sensor unit (4) includes a housing (4a) adapted to accommodate critical parts [not shown in Figures] of the at least one sensor unit (4), which is configured to detect or measure quantity of fuel in the fuel tank. The housing (4a) may include a first elongated slot (4b) and a second elongated slot (4c) configured to receive a ring portion (10a) for holding the first float arm (5a) and the second float arm (5b) respectively. The at least one sensor unit (4) is configured to detect level of fuel in the fuel tank, based on movement of the first float arm (5a) and the second float arm (5b).

Referring to Figure 4a in conjunction to Figure 1, the first float arm (5a) is pivotally connected to the at least one sensor unit (4) via the first elongated slot (4b). The first float arm (5a) is also slidably connected to one end of the second float arm (5b) [as shown in Figure 4b]. The other end of the second float arm (5b) includes a float (11). The float (11) is adapted to rise or fall depending on the level of fuel in the fuel tank, and accordingly operates the first float arm (5a) and the second float arm (5b) pivotally, to provide feedback to the at least one sensor unit (4). The second float arm (5b) is connected to the at least one sensor unit (4) via the second elongated slot (4c), wherein the second elongated slot (4c) converts the pivotal motion of the second float arm (5b) to linear motion, to provide required feedback to the at least one sensor unit (4).

Further, the second float arm (5b) includes a plurality of serrations (8b), wherein each of the plurality of serrations (8b) are adapted to receive a second locking member (10) for locking the second float arm (5b) with the first float arm (5a). The plurality of serrations facilitates adjusting length of the second float arm (5b) with the first float arm (5a) [as shown in figure 4d], based on the profile of the fuel tank. In an embodiment, the plurality of serrations facilitates adjustment of float arm radius, based on angular profile of the fuel tank.

In an embodiment, distance between each of the plurality of serrations (8b) are selected based on the dimensions of the fuel tank of vehicles in various segments, so that the length of the fuel suction tube (1) is adjusted corresponding to the profile of the fuel tank. In an embodiment, the distance between each of the plurality of serrations (8a) may be in a range of about 5mm to about 10 mm.

In an exemplary embodiment, the plurality of serrations (8a) are fifteen, which enable variation of the vertical height of the fuel suction tube (1) by fifteen levels. However, this should not be construed as a limitation in adjusting the height by only fifteen levels as different fuel tank dimensions may require adjustment of height by less than 15 levels or more than 15 levels. Thus, number of serrations varies based on design and dimension of the fuel tank.

In an embodiment, the first float arm (5a) is pivotally connected to the at least one sensor unit (4) via fasteners (12) [as shown in figure 4a].

In an embodiment, the second float arm (5b) is slidably connected to the first float arm (5a) via fastener (12) [as shown in figure 4a].

In an embodiment, the mounting flange (2) is a plate-like structure configured to be fastened to the fuel tank of the vehicle. In an exemplary embodiment, the mounting flange (2) is fastened at the top portion of the fuel tank. The mounting flange (2) at the top portion of the fuel tank ensures that the fuel suction tube (1) aligns vertically, and its aft end is positioned at the bottom most portion of the tank, thereby enable efficient pumping of fuel in the fuel tank.

In an embodiment, the first locking member (9) and the second locking member (10) is selected from at least one of a fastener, a spring loaded fastener, a snap-fit member and the like which serves the purpose and requirement.

In an embodiment, a bracket (3a) extends from the clamp (3) for fastening the at least one sensor unit (4) [as shown in Figure 3]. The bracket (3a) holds the at least one sensor unit (4) in position during operation, thereby preventing misalignment of the at least one sensor unit (4) during operation.

In another embodiment, the clamp (3) may be selected from at least one of a C-clamp, a U-clamp or any other clamp which serves design feasibility and requirement. The clamp is fastened to the fuel suction pipe (1) via fasteners (12) [as shown in Figure 3].

In an embodiment, the ring portion (10a) allows the second float arm (5b) to side through, may prevent misalignment of the second float arm (5b) while sliding with respect to the first float arm (5a). The ring portion (10a) may also act as a reinforcement member to the joint between the first float arm (5a) and the second float arm (5b).

In an embodiment, the second elongated slot (4c) while adjusting length of the second float arm (5b), also enables angular adjustment by the fastener (12) [shown in Figure 4c]. This configuration ensures that feedback received by the at least one sensor unit (4) by the movement of the first float arm (5a) and the second float arm (5b) is maintained.

In an embodiment, the at least one sensor unit (4) is selected from at least one of a piezoelectric sensor unit, a hall effect sensor unit and the like which serves the purpose. In an exemplary embodiment, the at least one sensor unit (4) is a Thin Film Resistor [TFR] unit.

In an embodiment, the at least one sensor unit (4) may be provided in a fluid system [not shown in Figures] for determining fluid level in the fluid system.

Equivalents
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances, where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

Referral Numerals
Description
100 Fuel level sensor assembly
1 Fuel suction pipe
1a First arm of the fuel suction pipe
2 Mounting flange
3 Clamp
3a Bracket extending from the clamp
4 At least one sensor unit
4a Housing of the at least one sensor unit
4b First elongated slot
4c Second elongated slot
5a First float arm
5b Second float arm
6 Fuel filter
7 Washer member
8a and 8b Plurality of serrations
9 First locking member
10 Second locking member
10a Ring portion in the second locking member
11 Float
12 Fasteners